How do you test and troubleshoot HMI SCADA projects before and after deployment?

1 Define the scope and requirements

The first step in testing and troubleshooting HMI SCADA projects is to define the scope and requirements of the project. You need to know what the system is supposed to do, how it will interact with the hardware and software components, what data it will collect and display, and what safety and security measures it will follow. You also need to document the specifications, standards, and protocols that the project will comply with. Having a clear and detailed scope and requirements will help you design, test, and troubleshoot the project more efficiently and effectively.

2 Develop and simulate the logic and graphics

The next step is to develop and simulate the logic and graphics of the HMI SCADA project. The logic is the code or program that defines the behavior and functionality of the system. The graphics are the visual elements that show the status and performance of the system. You can use various software tools and platforms to create and test the logic and graphics of your project, such as PLCs, HMIs, SCADA servers, and databases. You can also use simulation software to mimic the real-world conditions and scenarios that the system will face, such as input signals, alarms, events, and failures. By developing and simulating the logic and graphics, you can verify the functionality, usability, and reliability of the system before deploying it.

3 Perform the factory acceptance test

The third step in the HMI SCADA project is the factory acceptance test (FAT). This formal, comprehensive test verifies that the system meets the scope and requirements, and operates as expected. The FAT includes reviewing documentation and drawings, inspecting hardware and software components, testing communication and integration with other devices, testing logic and graphics under normal and abnormal conditions, testing data collection, storage, and analysis functions, testing security and backup features, testing user interface and user experience, and recording and resolving any issues or defects found. It should be conducted in a controlled environment with stakeholders present, such as the customer, vendor, engineer, and operator. Additionally, it should follow a predefined test plan with a test report and punch list generated afterwards.

4 Install and commission the system

The fourth step in the HMI SCADA project is to install and commission it at the site. This involves physically setting up the hardware and software components, verifying that the system is ready to run, transporting and handling equipment and materials, mounting and wiring hardware components, configuring and updating software components, connecting and testing communication, calibrating and tuning sensors, actuators, and controllers, testing logic and graphics under normal and abnormal conditions, testing data collection, storage, and analysis functions, testing security and backup features, testing user interface and user experience, as well as recording and resolving any issues or defects. All of this should be done in accordance with the design specifications, standards, protocols of the project. A predefined installation and commissioning plan and procedure should be followed to generate an installation report as well as a punch list.

5 Perform the site acceptance test

The fifth step of the HMI SCADA project is to perform the site acceptance test (SAT). This final and formal test confirms that the system is fully functional and operational at the site. The SAT includes reviewing the documentation and reports, inspecting hardware and software components, testing communication and integration with other devices, testing logic and graphics under normal and abnormal conditions, testing data collection, storage, and analysis functions, security and backup features, user interface and experience. It should be conducted in a real-world environment with stakeholders like the customer, vendor, engineer, and operator. Additionally, it should follow a predefined test plan and procedure to generate a test report and punch list.

6 Monitor and maintain the system

The sixth step of the HMI SCADA project is to monitor and maintain the system after deployment. This process involves observing and measuring system performance, as well as keeping it in good condition. It includes collecting and analyzing data, checking and updating hardware and software components, troubleshooting any issues or defects, performing preventive and corrective actions to improve reliability and efficiency, conducting periodic inspections, audits, and reviews of the system, and documenting and reporting any changes or incidents. All monitoring and maintenance should adhere to the operational requirements, standards, protocols, plan, and procedure of the project. Records and reports should also be generated.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?